Intelligent bottom pouring type pouring machine plug rod control system

Abstract

The invention provides an intelligent bottom pouring type casting machine plug rod control system, and relates to the technical field of casting machines. The intelligent bottom pouring type casting machine plug rod control system comprises a sensing acquisition module, a core control module, an execution driving module, a man-machine interaction module, a data management module and a safety protection module, and the output end of the sensing acquisition module is in real-time communication with the input end of the core control module through an industrial Ethernet; the core control module is used for transmitting the weight of molten metal, the position of a plug rod and the temperature data of a sprue gate, and the output end of the core control module and the input end of the execution driving module are synchronously controlled through an SERCOS-III protocol. Through dynamic vibration compensation weighing and LSTM neural network prediction closed-loop control, the pouring weight error is remarkably reduced, the over-pouring or under-pouring problem of traditional pouring is solved, the metal liquid flow state is optimized synchronously through nanoscale plug rod positioning, the high-end casting qualification rate is greatly increased, and metal raw materials are saved.

Description

TECHNICAL FIELD

[0001] The application relates to the technical field of pouring machines, in particular to an intelligent bottom-pouring machine plug rod control system. BACKGROUND

[0002] The plug rod of the intelligent bottom-pouring machine is a core executive component for controlling the metal liquid pouring process, and is equivalent to a "valve" of the pouring system. By accurately adjusting the opening degree and the motion track of the plug rod, the metal liquid flow, the flow rate and the pouring termination time can be accurately controlled.

[0003] The traditional open-loop control relies on manual adjustment or a simple electric mechanism, so that the existing bottom-pouring machine plug rod control has the problems of insufficient accuracy and response lag, and is difficult to cope with nonlinear working conditions such as metal liquid temperature change and flow state fluctuation, and is prone to cause large pouring weight deviation and high casting defect rate. SUMMARY

[0004] In view of the deficiencies of the prior art, the application provides an intelligent bottom-pouring machine plug rod control system, which solves the problems of insufficient accuracy and response lag of the bottom-pouring machine plug rod control.

[0005] To achieve the above purpose, the application is implemented by the following technical scheme: an intelligent bottom-pouring machine plug rod control system, comprising a sensing and collecting module, a core control module, an execution driving module, a man-machine interaction module, a data management module and a safety protection module, the output end of the sensing and collecting module is connected with the input end of the core control module through real-time communication of industrial Ethernet, and the metal liquid weight, the plug rod position and the pouring port temperature data are transmitted, the output end of the core control module is connected with the input end of the execution driving module through synchronous control of SERCOS-III protocol, the alarm signal of the safety protection module is directly connected with the emergency stop circuit of the execution driving module, the man-machine interaction module and the data management module are bidirectionally interacted through OPCUA protocol, process parameter configuration and defect data tracing are realized, a process parameter closed-loop optimization link is formed, the data management module synchronously stores the running data of each module, and provides a historical analysis report to the man-machine interaction module, the safety protection module sends an emergency stop instruction to the execution driving module through a hard-wired direct connection circuit, and the priority is higher than that of the core control.

[0006] Preferably, the sensing and collecting module comprises a dynamic vibration compensation weighing unit, a multi-band filtering algorithm is adopted to eliminate interference, and a metal liquid weight signal with an output accuracy of ±0.1% is output; a nanometer-level magnetic grating position detection unit with a resolution of ±0.001mm is adopted to feed back the plug rod opening degree in real time; a pouring port thermocouple array is adopted to monitor the temperature gradient with a 0.5s delay; and a three-dimensional force field sensor is adopted to deploy a six-point pressure array at the pouring port and construct a flow state pressure cloud.

[0007] Preferably, the core control module includes an adaptive fuzzy PID controller that dynamically adjusts gain parameters based on the temperature of the molten metal to generate a reference command for the opening degree of the plug rod; an LSTM end-point prediction unit that inputs weight, temperature, and position data and outputs a 50ms-ahead plug rod closing compensation; and a metal flow state simulation engine that simulates the pouring process and optimizes the plug rod motion trajectory, with the results being pushed to the human-machine interaction module warning interface.

[0008] Preferably, the execution driving module includes a high-torque servo motor that drives the plug rod up and down through a ball screw; a spring accumulator emergency retracting mechanism that responds to the safety module command to forcibly lift the plug rod 20mm within 0.1s; and a displacement feedback unit that returns the actual position error to the core control module.

[0009] Preferably, the execution process of the emergency retracting mechanism is as follows: Step one: the three-dimensional force field sensor detects a pressure > 3MPa and the acoustic emission instrument captures a solidification frequency of 100-200kHz; Step two: the spring accumulator is activated to release the pre-stored mechanical energy; Step three: the wedge cam mechanism converts rotational potential energy into vertical linear displacement of the plug rod; Step four: a 0.5MPa high-pressure argon gas purging sprue is opened for 2-3s; Step five: after the displacement is completed, a reset enable signal is sent to the human-machine interaction module.

[0010] Preferably, the safety protection module includes dual-redundant strain sensors that monitor the force state of the plug rod; an acoustic emission crack detector that identifies the metal solidification characteristic frequency; a super capacitor backup power supply that maintains the emergency stop circuit working for 30s when power is off; and a direct connection interrupt execution driving module when a pressure gradient mutation > 10kPa / mm is detected.

[0011] Preferably, the data management module records the raw data of the sensing module and the instruction data of the core control module every second, uploads the emergency stop events to the cloud platform through the MQTT protocol, marks the associated plug rod control parameters, and reversely generates a pouring process equipment comprehensive efficiency report for defective castings.

[0012] Preferably, the human-machine interaction module includes a three-dimensional dynamic monitoring interface that real-time maps the plug rod position, metal flow rate, and force field cloud map; a segmented pouring curve editor that sets weight and speed target values and issues them to the core control module; and a multi-level alarm board that displays the mechanical, electrical, and process wind of the safety protection module in a classified manner.

[0013] Preferably, when the sensing module fails, the core control module switches to an open-loop constant speed mode and alarms, when the safety module triggers an emergency stop, the data management module freezes the pouring data of this time and generates an analysis tag, and when the displacement error of the execution module is >0.1mm, the human-computer interaction module pops up a calibration guide.

[0014] The application provides an intelligent bottom pouring type pouring machine plunger control system. 1. The application realizes significant reduction of pouring weight error, improves the problems of over-pouring or under-pouring in traditional pouring, and optimizes the flow state of the metal liquid in nanometer plunger positioning synchronization, so that the qualified rate of high-end castings is greatly improved, and metal raw materials are saved.

[0015] 2. The application cooperates with real-time monitoring of a three-dimensional force field through a spring energy storage mechanical retraction mechanism, and a hard-wired direct connection interruption control instruction, so that when the pouring gate is frozen or the pressure is suddenly changed, the plunger is forced to be lifted and argon is blown, metal liquid spatter accidents are eliminated, major safety risks are reduced, and the stability of continuous production is ensured. BRIEF DESCRIPTION OF DRAWINGS

[0016] Figure 1 The application is a module cooperation display schematic diagram; Figure 2 The application is a plunger retraction process schematic diagram. DETAILED DESCRIPTION

[0017] The technical solutions in the embodiments of the application will be clearly and completely described below with reference to the drawings in the embodiments of the application. Obviously, the described embodiments are only part of the embodiments of the application, rather than all the embodiments of the application. Based on the embodiments in the application, all other embodiments obtained by those skilled in the art without creative work fall within the protection scope of the application.

[0018] Embodiment: As shown in Figure 1 and Figure 2 The application provides an intelligent bottom pouring type pouring machine plunger control system, which comprises a sensing and collecting module, a dynamic vibration compensation weighing unit: a multi-band filtering algorithm is used to eliminate mechanical vibration interference, and a metal liquid weight measurement with an accuracy of ±0.1% is provided; a nanometer magnetic scale position detection unit: the resolution is ±0.001mm, and the plunger opening position is fed back in real time; a pouring gate thermocouple array: a temperature gradient is monitored with a delay of 0.5 seconds, and the real-time nature of temperature data is ensured; a three-dimensional force field sensor: six-point pressure arrays are arranged at the pouring gate, and a metal liquid flow state pressure cloud map is constructed. Core control module Adaptive fuzzy PID controller: dynamically adjust PID parameters according to the temperature of the molten metal, optimize control response, LSTM end point prediction unit: predict the closing time of the plug rod based on historical data, compensate control instructions 50ms in advance, metal flow state simulation engine: preview the pouring process, generate optimized plug rod motion trajectory.

[0019] Execution driving module High-torque servo motor: drive the plug rod up and down through the ball screw, response accuracy up to ±0.01mm; spring energy storage emergency retreat mechanism: forcibly lift the plug rod 20mm within 0.1 seconds to prevent gate blockage; displacement feedback unit: real-time feedback of the actual position of the plug rod, forming a closed-loop control.

[0020] Safety protection module Dual-redundant strain sensors: cross-verify the force state of the plug rod to avoid single-point failure; acoustic emission crack detector: capture 100-200kHz metal solidification characteristic frequency, early warning; super capacitor backup power supply: maintain the emergency stop circuit working for 30 seconds when power is off, ensure system safety.

[0021] Human-computer interaction module Three-dimensional dynamic monitoring interface: real-time display of plug rod position, metal liquid flow and force field cloud map; segmented pouring curve editor: support multi-stage weight and speed curve configuration; multi-level alarm board: classified display of mechanical, electrical and process risk alarms.

[0022] Data management module Real-time data recording: collect and store sensor raw data and control instructions every second; cloud platform upload: real-time synchronization of emergency stop events and associated parameters through MQTT protocol; OEE analysis report: automatically generate equipment comprehensive efficiency report, support defect traceability.

[0023] Normal pouring process: The sensor acquisition module monitors the weight of the molten metal, the position of the plug rod and the temperature data in real time; the core control module calculates the plug rod opening degree through adaptive fuzzy PID, and the LSTM prediction unit compensates the end point error in advance; the execution driving module accurately adjusts the position of the plug rod according to the control instruction, and the displacement feedback unit ensures the accuracy; the data management module synchronously records the full data, and the human-computer interaction module visually displays the real-time state.

[0024] Emergency retreat, three-dimensional force field sensor detects pressure >3MPa and acoustic emission instrument captures solidification frequency.

[0025] Execution process: The activation spring accumulator releases the pre-stored mechanical energy; the wedge cam mechanism converts the rotational potential energy into the vertical linear displacement of the plunger; the system opens the 0.5 MPa high-pressure argon gas purging gate for 2-3 seconds to prevent the metal liquid from solidifying; the system freezes the current data and sends a reset request to the human-machine interface.

[0026] Fault handling strategy Sensor module failure: automatically switch to open-loop constant speed mode and trigger audible and light alarms.

[0027] Execution module error: when the displacement error is greater than 0.1 mm, the human-machine interface pops up a calibration guide.

[0028] Safety module trigger: emergency stop command is executed through a hard-wired direct connection circuit, with higher priority than the core control module.

[0029] Although embodiments of the present application have been shown and described, it is to be understood that various modifications, substitutions, replacements and changes can be made to these embodiments without departing from the principles and spirit of the present application, and the scope of the present application is defined by the appended claims and their equivalents.

Claims

1. An intelligent bottom pouring casting machine stopper rod control system, characterized in that: include: Sensing acquisition module, core control module, execution drive module, human-computer interaction module, data management module and safety protection module. The output end of the sensing acquisition module and the input end of the core control module communicate in real time through industrial Ethernet to transmit the metal liquid weight, plug rod position and pouring mouth temperature data. The output end of the core control module and the input end of the execution drive module are synchronously controlled through the SERCOS-III protocol. The alarm signal of the safety protection module is directly connected to the emergency stop circuit of the execution drive module. The human-computer interaction module and the data management module interact bidirectionally through the OPCUA protocol to realize process parameter configuration and defect data tracing, forming a closed-loop optimization link for process parameters. The data management module synchronously stores the operating data of each module and provides a historical analysis report to the human-computer interaction module. The safety protection module sends an emergency stop command to the execution drive module through a hard-wired direct circuit, with a higher priority than the core control module.

2. The intelligent bottom pouring casting machine stopper rod control system according to claim 1, characterized in that: The sensing acquisition module includes a dynamic vibration compensation weighing unit, which uses a multi-band filtering algorithm to eliminate interference and outputs a molten metal weight signal with an accuracy of ±0.1%; a nano-scale magnetic scale position detection unit with a resolution of ±0.001mm and real-time feedback of the plug rod opening; a pouring gate thermocouple array that monitors temperature gradients with a 0.5s delay; and a three-dimensional force field sensor that deploys a six-point pressure array at the pouring gate to construct a flow pressure cloud.

3. The intelligent bottom pouring casting machine stopper rod control system according to claim 1, characterized in that: The core control module includes an adaptive fuzzy PID controller that dynamically adjusts the gain parameters according to the molten metal temperature to generate a reference command for the stopper rod opening; an LSTM endpoint prediction unit that inputs weight, temperature, and position data and outputs a 50ms early stopper rod closing compensation; Metal flow simulation engine: Previews the pouring process and optimizes the stopper rod motion trajectory, with the results pushed to the human-computer interaction module warning interface.

4. The intelligent bottom pouring casting machine stopper rod control system according to claim 1, characterized in that: The execution drive module includes a high-torque servo motor that drives the plug rod up and down through a ball screw; a spring-loaded emergency retraction mechanism that responds to the safety module's instructions and forcibly lifts the plug rod 20mm within 0.1s; The displacement feedback unit transmits the actual position error back to the core control module.

5. The intelligent bottom pouring casting machine stopper rod control system according to claim 4, characterized in that: The execution process of the emergency evacuation mechanism is as follows: Step 1: The three-dimensional force field sensor detects a pressure greater than 3 MPa and the acoustic emission instrument captures a coagulation frequency of 100-200 kHz; Step 2: Activate the spring accumulator to release the pre-stored mechanical energy; Step 3: The wedge-shaped cam mechanism converts the rotational potential energy into vertical linear displacement of the plug rod; Step 4: Simultaneously open 0.5MPa high-pressure argon gas to purge the pouring port for 2-3s; Step 5: After the displacement is completed, a reset enable signal is sent to the human-computer interaction module.

6. The intelligent bottom pouring casting machine stopper rod control system according to claim 1, characterized in that: The safety protection module includes dual redundant strain sensors to monitor the stress state of the plug rod; an acoustic emission crack detector to identify the characteristic frequency of metal solidification; a supercapacitor backup power supply to maintain the emergency stop circuit operation for 30 seconds in the event of a power outage; and a direct interrupt execution drive module when a sudden pressure gradient change of >10kPa / mm is detected.

7. The intelligent bottom pouring casting machine stopper rod control system according to claim 1, characterized in that: The data management module records the raw data of the sensor module and the command data of the core control module every second, uploads the emergency stop event to the cloud platform through the MQTT protocol, marks the associated plug rod control parameters, and reversely generates a comprehensive efficiency report of the casting process equipment of the defective casting.

8. The intelligent bottom pouring casting machine stopper rod control system according to claim 1, characterized in that: The human-computer interaction module includes a three-dimensional dynamic monitoring interface: real-time mapping of the plug rod position, molten metal flow and force field cloud map, a segmented pouring curve editor: setting weight and speed target values ​​and sending them to the core control module, and a multi-level alarm dashboard: categorized display of the mechanical, electrical and process risks of the safety protection module.

9. The intelligent bottom pouring casting machine stopper rod control system according to claim 1, characterized in that: When the sensing module fails, the core control module switches to open-loop constant speed mode and issues an alarm. When the safety module triggers an emergency stop, the data management module freezes the pouring data and generates an analysis tag. When the displacement error of the execution module is greater than 0.1mm, the human-computer interaction module pops up a calibration guide.

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